Download Service manual

Wall hung, fanflue, roomsealed, high efficiency gas boiler
Service manual
ActivA Plus
Models
Activ A Plus
Activ A Plus
Activ A Plus
Activ A Plus
30C
35C
16S
25S
Leave this manual adjacent to the gas meter
Warning
Service / repairs must be carried out, only by a qualified
Gas Safety Registered Engineer, who will be responsible for
the current Regulations for gas appliances.
Table of contents
1 Overall information . . . . . . . . . . . . . . . . . . . . . . . . . 4
12 Primary circuit flow switch . . . . . . . . . . . . . . . . 37
2 General access and emptying hydraulic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
13 Expansion vessel and pressure gauge . . . . . . 38
1.1
1.2
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Case panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Main electronic p.c.b. box . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Emptying the primary circuit . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Emptying the d.h.w. circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12.2Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
12.3Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
13.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13.2Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13.3 Removal of the expansion vessel . . . . . . . . . . . . . . . . . . . . 38
14D.h.w. flow switch, filter and flow limiter . . 39
Wiring diagram Activ A Plus 30C - Activ A Plus 35C . . . . . . . 8
Wiring diagram Activ A Plus 16S - Activ A Plus 25S . . . . . . . 9
Circuit voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
14.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
14.2 Description and location of parts - (Figure 14.2) . . . . . . . . 39
14.3 Removal of the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
14.4Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
14.5 Removal of the flow switch group and d.h.w. circuit filter . . 40
14.6 Flow limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
15 TEMPERATURE PROBE . . . . . . . . . . . . . . . . . . . . . . . . . 41
3Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1
3.2
3.3
4.1
Display diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Condensing heat exchanger . . . . . . . . . . . . . . . . 14
5.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6D.h.w. heat exchanger . . . . . . . . . . . . . . . . . . . . . . . 16
6.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
7.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3 Removal pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.4 Removal electrical capacitor . . . . . . . . . . . . . . . . . . . . . . . . 18
8 Three way diverter valve . . . . . . . . . . . . . . . . . . . 19
8.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.2Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.3 Removal of the electric actuator . . . . . . . . . . . . . . . . . . . . . 19
8.4 Removal of the three way diverter valve . . . . . . . . . . . . . . 20
8.5 Removal of the diverter group . . . . . . . . . . . . . . . . . . . . . . 20
9Main electronic control/ignition p.c.b. . . . . . 21
9.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.2 Selection and adjustment devices . . . . . . . . . . . . . . . . . . . 21
9.3 Checking the temperature . . . . . . . . . . . . . . . . . . . . . . . . . 22
9.4 Setting the boiler control function modes . . . . . . . . . . . . . . 23
9.5Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.6 Removal of the electronic control p.c.b . . . . . . . . . . . . . . . 26
9.7 Thermal control in the
mode . . . . . . . . . . . . . . . . . . . . 27
9.8 Thermal control in the
mode . . . . . . . . . . . . . . . . . . . . 28
10 Control panel electronic p.c.b. . . . . . . . . . . . . . 29
10.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.2 Normaly information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.3 Info modality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.4 Function modes setting modality . . . . . . . . . . . . . . . . . . . . 31
10.5 Removal of the control panel electronic p.c.b . . . . . . . . . . . 31
10.6 Removal of the interface electronic p.c.b . . . . . . . . . . . . . . 31
15.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
15.2Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
15.3 Removal of the c.h. Temperature probes . . . . . . . . . . . . . . 41
15.4 Removal of the d.h.w. Temperature probes . . . . . . . . . . . . 42
16By-pass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
16.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
16.2Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
17Fan and Air box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
17.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
17.2 Removal of the Air box and the Fan . . . . . . . . . . . . . . . . . . 44
18Ignition, detection electrodes and burner . 45
18.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
18.2 Removal of the Ignition and detection electrodes . . . . . . . . 45
18.3 Removal of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
18.4 Removal of the front insulation panel . . . . . . . . . . . . . . . . . 46
18.5 Removal of the rear insulation . . . . . . . . . . . . . . . . . . . . . . 46
18.6Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
19 Safety thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . 48
19.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
19.2Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
19.3Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
20Flue temperature probe NTC and Safety thermal fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
20.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
20.2Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
20.3Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
21 Condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
21.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
21.2 Check the cleanness of the trap . . . . . . . . . . . . . . . . . . . . . 51
21.3Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
22 Short spare parts list . . . . . . . . . . . . . . . . . . . . . . 52
11gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.1Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.2 Description of the parts - (Figure 11.2) . . . . . . . . . . . . . . . . 33
11.3Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.4Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
11.5 Removal of the gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . 36
-3-
OVERALL INFORMATION
1
Overall information
1.1 Overall View
Flue temperature
probe NTC
Condensing
heat exchanger
Safety
thermostat
Expansion
vessel
Ighition
electrodes
Detection
electrode
Pipe silencer
Burner
Airbox
(air/gasmixer)
Fan
Electronic controlbox
Three way diverter valve
D.h.w.heat
exchanger
Gas restrictor
Condensate
trap
Main circuit
pressure switch
C.h. pressure
relief valve
Electric actuator
diverter valve
D.h.w. temperature probe
Figure 1.1
Gas valve
D.h.w.
flow switch
Control
panel
Automatic air
purger valve
Pump
1.2 Hydraulic diagram
Central heating (c.h.) operation
C.h.
water return
Figure 1.2
-4-
C.h.
water flow
Domestic hot water (d.h.w.) operation
D.h.w. D.h.w.
inlet
outlet
GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS
2
General access and emptying
hydraulic circuits
Pull the lower part of the front panel and lift it upwards (Figure
2.3).
2.1 Nomenclature
C
1
C
2
5
Figure 2.3
4
3
To remove the side panels loosen the screws B (Figure 2.2) and
C (Figure 2.3).
Pull the side panels towards the outside.
To Fit the case panels
Fit the side case panels.
Figure 2.1
1
2
3
4
5
Right side panel
Front panel
Control panel
Main electronic p.c.b. box
Left side panel
Warning: Fit the front panel hooking it on the upper
side.
2.2 Case panels
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
Push the spring towards the internal side of the boiler and simultaneously push the front case panel until it is completely hold in
place (Figure 2.4 step 1, 2).
Repeat the same operation on the opposite side of the front panel (Figure 2.4 step 3, 4).
Ensure that the front panel edge is close-fitting to the side panels.
Lock in place the panel with the appropriate screws.
For the most part of the check and maintenance operations it is
necessary to remove one or more panels of the case.
The side panels can be removed only after the removal of the
front panel.
To remove the front panel loosen screws A (Figure 2.2), lift the
panel and remove it.
3
A
1
B
4
2
B
Figure 2.4
Figure 2.2 - bottom view of the boiler
-5-
GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS
2.3 Control panel
2.4 Main electronic p.c.b. box
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
To gain access to the parts located inside the control panel proceed as follows:
1 Remove the front panel of the case
To gain access to the parts located intomain electronic p.c.b. box
proceed as follows:
1 Remove the front panel of the case.
2 Unscrew the screws D and E (Figure 2.5).
3 Free the hooks indicated and rotate the lid towards left.
Terminal block lid removal
2 To remove the terminal block lid F (Figure 2.7), free the front
hooks.
E
D
F
te
ta
Ro
te
ta
Ro
Figure 2.5
Figure 2.7
4 To access to the parts located behind the control panel turn it
as shown in Figure 2.6.
3 Slightly rotate the lid as indicated by the curved arrow and
free the rear hooks.
4 Remove the lid.
Main electronic p.c.b. lid removal
To get access to the main electronic p.c.b.:
5 Pull the box that contains the electronic p.c.b. and rotate it
(Figure 2.8).
Figure 2.6
Figure 2.8
-6-
GENERAL ACCESS AND EMPTYING HYDRAULIC CIRCUITS
6 Remove the terminal block lid F (Figure 2.7).
7 Free the hooks placed on the three sides indicated and rotate
the lid towards left (Figure 2.9).
I
Figure 2.12
Figure 2.9
2.6 Emptying the d.h.w. circuit
1 Close the d.c.w. inlet cock H (Figure 2.10).
2 Open one or more hot water taps until the boiler has been
completely emptied.
2.5 Emptying the primary circuit
1 Close the c.h. circuit flow and return cocks G (Figure 2.10).
H
G
Figure 2.10
2 Remove the front and right panels of the boiler.
3 Open the drain tap I (Figure 2.11 combi or Figure 2.12 only
c.h.) until the boiler is completely emptied.
4 To help the draining of the primary circuit loose the condensing heat exchanger air purger valve.
CLOSED
OPEN
I
Figure 2.11
-7-
DIAGRAMS
3
Diagrams
3.1 Wiring diagram Activ A Plus 30C - Activ A Plus 35C
Three way
diverter valve
Pump
1
Fan
1
bu
bn
bu
gnye
M
~
bn
gnye
bu
bk
bu
wh
rd
4
2
Flame detection
electrode
Ignition
electrodes
bk
bu
~
3
wh
rd
gnye
bn
M
bn
bu
bk
3
Gas valve
wh
gy
wh
t
C.h. temperature
probe NTC
return
t
Flue temp.
probe NTC
wh
wh
bk
bk
bn
rd
bu
bu
bn
rd
wh
bk
bu
bu
og
bk
t
Safety
thermal fuse
t
D.h.w. outlet
temperature
probe NTC
rd
bu
bk
rd
rd
rd
rd
bu
rd
wh
rd
gy
bn
wh
bu
bk
bu
wh
rd
wh
wh
bk
5V
GND
wh
OUT
D.h.w. flow
switch
Primary circuit
pressure switch
rd
bn
bk
5V
GND
wh
OUT
bk
bk
bu
gnye
wh
wh
bu
t
bu
bk
bk
bu
bn
bk
Safety
thermostat
bk
wh
t
bk
wh
bk
rd
rd
wh
bu
gnye
L
bn
3
ye
2
bk
1
wh
rd
wh
N
bk
bu
br
br
bn = brown
bu = blue
bk = black
wh = white
rd = red
gy = grey
Figure 3.1
-8-
gn = green
ye = yellow
vt = violet
og = orange
gnye = green/yellow
rdwh = red/white
bu
og
wh
ye
bk
C.h. temperature
probe NTC
flow
D.h.w. inlet
temperature
probe NTC
DIAGRAMS
3.2 Wiring diagram Activ A Plus 16S - Activ A Plus 25S
Three way
diverter valve
Pump
1
Fan
1
bu
bn
bu
gnye
M
~
bn
gnye
bu
bk
bu
wh
rd
4
2
Flame detection
electrode
Ignition
electrodes
bk
bu
~
3
wh
rd
gnye
bn
M
bn
bu
bk
3
Gas valve
wh
gy
wh
t
C.h. temperature
probe NTC
return
t
Flue temp.
probe NTC
wh
rd
rd
bk
bn
wh
wh
bk
bk
gy
bu
bk
bu
wh
rd
wh
wh
bk
t
bu
thermal fuse
bn
bu
bn
rd
wh
bk
bu
bu
og
bk
rd
bn
bk
5V
GND
wh
OUT
bk
bk
bu
gnye
wh
wh
bu
t
bu
bk
bk
bu
bn
bk
bk
Primary circuit
pressure switch
C.h. temperature
probe NTC
flow
Safety
thermostat
bk
bk
rd
rd
N
bu
gnye
L
bn
3
ye
2
bk
1
wh
rd
bk
bu
br
br
bn = brown
bu = blue
bk = black
wh = white
rd = red
gy = grey
bu
og
wh
ye
bk
gn = green
ye = yellow
vt = violet
og = orange
gnye = green/yellow
rdwh = red/white
Figure 3.2
-9-
DIAGRAMS
3.3 Circuit voltages
during c.h. or d.h.w. operation
Electrical voltages with burner on
only during c.h. operation
only during d.h.w. operation
3 way
diverter valve
0...32 Hz
Supply network
Figure 3.3
- 10 -
0
230~
1
230~
0
230~
230~
230~
33...200 Hz
D.h.w.
Flow switch
0
Gas valve
Fan
Main circuit
pressure switch
Safety
thermostat
- 11 Appliance lock--- out (*)
E20
E14
E13
E12
E11
E10
--(1)
--- 21.1
(3)
--(2)
Gas supply line
Power supply line
Flue pipes
--(4)
5
7.2 8.2 14.3
6
D.h.w. heat exchanger
Condensing heat exchanger
Pump
Diverter valve
9.5
10 11.4 12.2 14.5
Components to check
E09
E08
E07
E06
E04
E05
E03
E02
E01
Defect
↓
Section of the manual →
(note ref. in brackets)
Disp
play indic
i catess ”E”
Cond. drain pipe and trap
C.h. circuit
D.h.w. circuit
D.h.w. flow switch
Fuses (Electronic p.c.b.)
Main electronic p.c.b.
Boiler settings
Control panel electr. p.c.b.
Gas valve
Main circuit pressure switch
D.h.w. filter
15.2
Main circuit temp. probe
D.h.w. temp. probe
16
17
Fan / air restrictor
By--- pass valve
18.4
Ignition electrode
Detection electrode
19.2 19.2 20.1
Safety thermostat
Gas restrictor
Flue temp. probe NTC
--(7)
Expansion vessel
---
Pressure gauge
---
---
External temp. probe
Safety valve
4
Fault finding
FAult finding
Gas supply line
Power supply line
Flue pipes
C.h. circuit
2
3
D.h.w. circuit
Water leaks from the safety valve
when the boiler is off.
---
* Lock out is indicated as “ E ” on the display.
1
Check for 230V~ between line (L) and neutral (N)
Verify the integrity of supply cable, plug and external fuses.
Useful information can be obtained also from the
optical indication given by the appliance display
(see section 4.1).
Note
5
4
Water leaks from the safety valve
during operation on c/h
---
Fuses (Electronic p.c.b.)
9.5
Main electronic p.c.b.
Control panel electr. p.c.b.
Gas valve
(8)
Main circuit temp. probe
D.h.w. temp. probe
Ignition electrode
--(7)
---
---
---
d.h.w. pressure too high or flow rate too high. If necessary insert a flow rate limiter (14.6).
The boiler doesn’t reach the nominal heat input.
8
9
Check the pressurization of the expansion vessel. Refer to the
installation manual for proper values.
Detection electrode
7
By--- pass valve
19.2 19.2 20.1
Safety thermostat
Using the flue analyzer, check the CO 2 value of the flue gases.
This reading is a reference value for the gas valve setting.
18.4
Safety valve
6
17
Fan / air restrictor
16
Gas restrictor
Main circuit pressure switch
15.2
Flue temp. probe NTC
10 11.4 12.2 14.5
D.h.w. filter
Boiler settings
Check the polarity of line and neutral connection
Check the gas supply pipe and isolation tap for gas tightness.
Check for soundness and absence of obstructions. Verify that
the flue terminal is correctly installed (see clearances) and ensure that exhaust gas is not sucked back by the boiler.
Check for soundness of the circuit and verify its correct filling
(see also installation manual).
A jammed by--- pass could cause the over--- heating of the main
circuit and the intervention of the safety thermostat.
Low d.h.w. flow rate
Poor c.h. / d.h.w. temperature
(9)
Appliance lock--- out (*)
Poor d.h.w. temperature. Regular
operation in c/h mode.
Noisy bolier
Incorrect modulation
7.2 5 8.2 14.3
6
Condensing heat exchanger
On c/h mode the temperature of
the main circuit reaches 90 C and
the c/h system does not heat.
The boiler operates correctly on
d.h.w. mode.
--(4)
Pump
--(2)
D.h.w. heat exchanger
Diverter valve
The boiler does not supply d.h.w.
(cold water from the tap).
Regular operation in c/h mode even
during a drawing off d.h.w.
The boiler does not start either in
c/h or d.h.w. mode.
The control panel display OFF
Fan still.
Defect
↓
--- 21.1
(3)
Cond. drain pipe and trap
--(1)
Expansion vessel
Section of the manual →
(note ref. in brackets)
D.h.w. flow switch
No ””Er” inddicatition o
on di
display
Pressure gauge
- 12 External temp. probe
Components to check
FAult finding
FAult finding
4.1 Display diagnostic
The display indications provide help in the diagnosis of fault finding.
The control panel display gives other information for the user.
The following table gives fault code, error and the reson for the
fault.
E01 + RESET
Lack of burner ignition on safety lockout
E02 + RESET
Safety thermostat intervention lockout
E03 + RESET
General lockout
E04 +
Little pressure in the system or pressure
transducer disconnected
E05 +
Pressure switch anomaly (if present)
E06 +
Faulty c.h. temp. probe NTC1 or NTC2
E07 +
Faulty d.h.w. temp. probe NTC
E08 +
Faulty external temp. probe NTC (with K
set)
E09 +
Faulty flue temp. probe NTC (if present)
E10 + RESET
Flue probe intervention lockout (if present)
E11 + RESET
Flame detection error
E12 +
Failure return NTC probe
E13 +
∆T delivery-return > 40K (if foreseen)
E14 + RESET
Faulty pump or primary temperature above
105°C
E14 +
Absence of flow from temperature gradient
(>2K/s)
E20 + RESET
Lockout EVG
E21 + RESET
Lockout EVG
E22 + RESET
Lockout EVG
E23 + RESET
Lockout EVG
E24 + RESET
Abnormal combustion ignition lock
E25 + RESET
Abnormal combustion operation lock
E69 +
Wiring error lockout
E99 +
Boiler not configured
L01
Primary circuit temp. limit during D.h.w.
operation
- 13 -
Condensing heat exchanger
5
Condensing heat exchanger
5.1 Function
The Condensing heat exchanger A in (Figure 5.1) has the function of transferring heat produced from combustion of the gas
and from the flue exhausted gas to the water circulating in it.
H
F
A
J
G
C
N
I
E
D
K
L
B
Figure 5.1
By reducing the combustion products temperature, the latent
heat of the vapour is transferred to the water circuit, allowing an
extra gain of useful heat.
The condensed vapour is then drained through the condensate
trap B and the draining pipe C.
5.2 Removal
M
Figure 5.2
10 Loosen the connection M and slightly move the pipe N upwards, turn it towards left (Figure 5.2) and then move the pipe
downwards freeing it from the Condensing heat exchanger.
Warning: isolate the boiler from the mains electricity
supply before removing any covering or component.
R
1 Disconnect the flue system from the boiler.
2 Remove the fan group (rubber pipe, gas pipe) following the
instructions from 1 to 6 in section "Removal of the Air box and
the Fan" page 44.
3 Disconnect the detection electrode connector D, the ignition
electrodes connector E and the earth wire F.
4 Disconnect the fan connector G by pressing the plastic hook
placed on the side of the connector (Figure 5.2).
5 Unscrew the nuts H (Figure 5.2).
6 Remove the fan-burner group I.
Q
7 Empty the primary circuit of the boiler.
8 Remove the clips J (Figure 5.2).
9 Loosen the connection K and slightly move the pipe L upwards, turn it towards left (Figure 5.2) and then move the pipe
downwards freeing it from the Condensing heat exchanger.
P
O
Figure 5.3
11 Using pliers, remove the spring O moving it downwards and
disconnect the rubber pipe P (Figure 5.3).
- 14 -
Condensing heat exchanger
12 Unscrew the screws Q and remove the clamps (Figure 5.3).
13 Disconnect the two connectors R by pressing the plastic hook
placed on the side of the connector (Figure 5.3).
14 Remove the Condensing heat exchanger by levering it and
sliding it forwards.
15 Reassemble the Condensing heat exchanger carrying out
the removal operations in reverse order.
Ensure to tighten the nuts H - Figure 5.2 firmly.
5.3 Cleaning
If there are deposits of dirt on the coil of the Condensing heat
exchanger, clean with a bristle paintbrush and remove the dust
with a hoover.
Warning: After cleaning or replacement as detailed
above, if it deemed necessary to undertake a combustion analysis as detailed in chapter 11.3 section
11.
S
Figure 5.4
Caution:
After any periodical servicing or disturbance the combustion
chamber silicon seal S Figure 5.4 must be fully inspected and
replaced at the discretion of the service engineer.
After any disturbance to the chamber door seal the appliance
must undergo a full analytical combustion performance check.
- 15 -
D.h.w. heat exchanger
6
D.h.w. heat exchanger
A
6.1 Function
The d.h.w heat exchanger A in Figure 6.1 and Figure 6.3 allows
the instantaneous transfer of heat from the primary hydraulic circuit to the water destined for d.h.w use.
B
A
B
Figure 6.3
7 Move the exchanger towards the rear of the boiler and extract
it to the left.
Reassemble the d.h.w. heat exchanger carrying out the removal
operations in the reverse order.
Warning: to lubricate the O-ring gaskets exclusive-
ly use a silicone base grease compatible to be in
contact with foods and approved by the local water
Authorities.
Warning: When reassembling the exchanger be sure
to put the off center location/securing pin indicated
in Figure 6.4 towards the left side of the boiler.
Figure 6.1
The schematic structure is shown in Figure 6.2.
Figure 6.4
Primary hydraulic circuit
Domestic hot water circuit
Figure 6.2
6.2 Removal
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove the panels of the case.
2 Empty the primary circuit and the d.h.w circuit of the boiler.
3 Remove the control panel following the instructions from 4 in
section 2.3.
4 Remove main electronic p.c.b. box following the instructions
from 5 in section 2.4.
5 Remove the pump following the instructions in section 7.3.
6 Completely unscrew the Allen key screws B in Figure 6.3
which hold the exchanger to the plastic groups.
- 16 -
PUMP
7
PUMP
7.1 Function
The pump A in Figure 7.1 and Figure 7.3 has the function of making the water in the main circuit circulate through the main condensing heat exchanger and therefore through the c.h. system
(during the c.h. function) or through the secondary heat exchanger (during the d.h.w. function).
12
34
5 6
A
Figure 7.2
Electrical resistance of the windings (at ambient temperature)
must be:
COIL
resistance
1-4
110 Ω
1-6
215 Ω
2-3
0Ω
2-5
230 Ω
3-5
230 Ω
4-6
110 Ω
Figure 7.1
Check the absence of starting defects.
7.2 Checks
Warning: isolate the boiler from the mains electricity
supply before removing any covering or component.
Check that the pump is not seized and that the movement of
the rotor is not subject to mechanical impediments.
With the boiler off, remove the front panel. Remove the air release plug of the pump and turn the rotor with a screwdriver.
With the boiler off remove the front case panel.
Remove the air release plug from the pump. Start the boiler and
with a screwdriver, turn the rotor in the direction of the arrow.
If there is a defect in starting, the rotor will begin to turn normally
only starting it manually.
Check that the impeller is integral with the rotor.
With the boiler off remove the front and right hand side case panels, lower the control panel and empty the primary circuit.
Remove the pump head by undoing the screws which hold it to the
pump body and check that the impeller is firmly joined to the rotor
Check the electrical continuity.
With the boiler off, remove the front panel and disconnect the
connector B (Figure 7.3).
Measure the electrical resistance between the pump supply connections.
- 17 -
PUMP
7.3 Removal pump
7.4 Removal electrical capacitor
Warning: isolate the boiler from the mains electricity
supply before removing any covering or component.
Warning: isolate the boiler from the mains electricity
supply before removing any covering or component.
1 Remove the front and right hand side case panels.
1 Remove the front and right hand side case panels.
2 Empty the primary circuit of the boiler.
2 Disconnect the connector B (Figure 7.3) following the indications given on the connector box.
3 Disconnect the connector B (Figure 7.3) following the indications given on the connector box.
4 Disconnect the earth connector C.
3 Remove the connector K of the cover box by levering with a
screwdriver in as shown in (Figure 7.4)
J
K
H
I
G
F
C
Figure 7.4
4 Remove the capacitor connection block L freeing it from the
hook M and pulling it as indicated by the arrow (Figure 7.5).
L
B
A
D
E
Figure 7.3
5 Loosen the connection G,and pull up and turn to the left the
pipe H.
6 Remove the fork F, loosen the connection J and remove the
pipe I.
7 Remove the locking plate D.
8 Unscrew the two screws E that hold the pump on the frame
and remove the pump.
Reassemble the pump carrying out the removal operations in the
reverse order. When reassembling the pump, check the correct
location of the O-ring gasket in the inlet port of the pump that
seals the connection between the pump and the plastic group.
- 18 -
Figure 7.5
M
Three way diverter valve
8
Three way diverter valve
8.1 Function
The diverter valve A (Figure 8.1) has the function of modifying the
hydraulic circuit of the boiler by means of an electric command
given by the electronic control p.c.b. in order to send the water
that exits the primary heat exchanger towards the c.h. system or
towards the d.h.w. heat exchanger.
B
Spindle visible
1 2
3
9,4 Kohm
Open circuit
230 V
0V
bk bu bn
bk = black
bu = blue
bn = brown
Figure 8.2 D.h.w. mode
A
B
Spindle not visible
Figure 8.1
1 2
3
Open circuit
9,4 Kohm
8.2 Checks
Figure 8.2 indicates the relationship between the electric command coming from the electronic control p.c.b. and the position
of the actuator B (brass spindle) when the boiler operates in
d.h.w. mode.
Figure 8.3 indicates the relationship between the electric command coming from the electronic control p.c.b. and the position
of the actuator B (brass spindle) when the boiler operates in c.h.
mode.
In both figures the relationship between the position of the actuator and the resistance of the motor windings (the motor must be
disconnected from the wiring) is also given.
230 V
0V
bk bu bn
Warning: check the electrical continuity.
bk = black
bu = blue
bn = brown
Figure 8.3 C.h. mode
8.3 Removal of the electric actuator
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove the front case panel.
2 Disconnect the connectors C (Figure 8.4).
3 Remove the fixing spring D and remove the actuator E.
Reassemble the actuator carrying out the removal operations
in the reverse order.
When reassembling the actuator, refer to Figure 8.3 or to the
wiring diagram in section 3 for the correct wiring connection.
- 19 -
Three way diverter valve
8.5 Removal of the diverter group
C
D
1 Remove the front and both side case panels.
2 Empty the primary circuit and the d.h.w circuit of the boiler.
3 Remove the electric actuator (section "Removal of the electric actuator" page 19).
4 Remove the fixing spring I (Figure 8.6) and remove the primary circuit flow switch J.
E
J
I
Figure 8.4
8.4 Removal of the three way diverter valve
1 Remove the front and both side case panels.
2 Empty the primary circuit and the d.h.w circuit of the boiler.
3 Remove the electric actuator (see "Removal of the electric
actuator" page 19).
4 Remove the fixing spring F (Figure 8.5)
5 Remove the threewaydiverter valve G by levering with a
screwdriver in as shown in Figure 8.5.
G
Figure 8.6
5 Disconnect d.h.w. temperature probe K.
L
F
M
K
Figure 8.7
H
Figure 8.5
6 Unscrew the connector L (Figure 8.7), the c.h. flow connector
and the d.h.w. outlet connector.
7 Remove the d.h.w. heat exchanger (see "Removal" page
16).
8 Unscrew the screw M and remove the diverter group.
Reassemble the three way diverter valve carrying out the removal operations in the reverse order.
9 Reassemble the diverter group carrying out the removal operations in the reverse order.
Warning: to lubricate the O-ring gaskets exclusively
Warning: to lubricate the O-ring gaskets exclusively
use a silicone base grease compatible to be in contact with foods and approved by the local water Authorities.
Attention. When reassembling the three way diverter valve
be sure that the three way diverter is correctly oriented by
matching the reference H with the notch of the water group
Figure 8.5.
- 20 -
use a silicone base grease compatible to be in contact with foods and approved by the local water Authorities.
MAIN Electronic control/ignition p.c.b.
9
Main electronic control/ignition
p.c.b.
9.1 Function
Inlet Information
On the Main electronic control/ignition
p.c.b. ......
Function control
C.h. temperature adjustment
D.h.w. temperature adjustment
Boiler reset button
(printed circuit board p.c.b.)
From other boiler devices....
C.h. temperature probe NTC
D.h.w. temperature probe NTC
D.h.w. flow switch
Primary circuit pressure switch
Flue temperature probe NTC
Safety thermostat
Flame detection electrode
Room thermostat (if fitted)
Time switch (if fitted)
The fundamental function of the Main electronic control/ignition
p.c.b. is that of controlling the boiler in relation to the external
needs (i.e. heating the dwelling or heating the water for d.h.w.
use) and operating in order to keep the temperature of the
hydraulic circuits constant.
This is obviously possible within the useful power and maximum
working temperature limits foreseen.
Generally, the Main electronic control/ignition p.c.b. receives
inlet information coming from the boiler (the sensors) or from the
outside (printed circuit board p.c.b., room thermostat, etc.), processes it and consequently acts with outlet commands on other
components of the boiler (Figure 9.1).
The Main electronic control/ignition p.c.b. is also a full sequence ignition device and does a sequence of operations (ignition
cycle) which lead to the ignition of the gas at the burner.
It checks the presence of the flame during the entire period in
which it is activated and supplies the fan regulating its speed.
The Main electronic control/ignition p.c.b. has a safety function
and any incorrect interventions or tampering can result in conditions of dangerous functioning of the boiler.
The Main electronic control/ignition p.c.b. can lock the functioning of the boiler (lock state) and stop its functioning up to the
resetting intervention. The lock-out is signalled on the display of
the printed circuit board p.c.b. and can be reset only by using the
boiler reset button placed on the control panel electronic p.c.b.
(see section 10.1).
Some components which are connected to the device can activate the lock state. The causes of a lock state could be:
• The intervention of the safety thermostat (overheat of the primary circuit).
• The intervention of the flue temperature probe (overheat of the
combustion products).
• A fault on gas supply.
• Faulty ignition (faulty ignition electrodes, their wiring or connection).
• Faulty flame detection (faulty detection electrode, its wiring or
connection).
• Faulty condensate drainage.
• Faulty gas valve (faulty on-off operators or not electrically supplied).
• Faulty Main electronic control/ignition p.c.b..
Other components like the primary circuit pressure switch can
temporarily stop the ignition of the burner but allow its ignition
when the cause of the intervention has stopped.
Figure 9.14 and Figure 9.15 show the sequence of the operations that are carried out at the start of every ignition cycle and
during normal functioning.
Outlet command
Pump
Three way diverter valve
Gas valve
Fan
Ignition electrodes
Display indicates “Er”*
*control panel electronic p.c.b.
9.2 Selection and adjustment devices
On the Main electronic control/ignition p.c.b. several selection,
adjustment and protection devices are located. (Figure 9.2).
Some of these devices are directly accessible by the user (function control, temperature adjustment etc.) others, like the fuses,
are accessible by removing the main electronic p.c.b. lid.
Figure 9.1
- 21 -
MAIN Electronic control/ignition p.c.b.
1
2
3
4
5
14
6
13
7
12
11
Figure 9.2
8
10
9
1 Connector - ignition electrode.
2 Connector - flame detection electrode
3 Connector - controler fan
4 Connector - flue temperature probe NTC
5 Connector - d.h.w. temperature probe NTC, d.h.w. flow switch
and external temperature probe (optional)
6 Connector - Primary circuit pressure switch
7 Connector - safety thermostat and c.h. temperature probe
NTC
8 Connector - remote control (optional)
9 Connector - display and function control / c.h. / d.h.w. temperature adjustment control panel p.c.b.
10 Fuse F1, F2 2A F
11 Connector - electric supply Main electronic control/ignition
p.c.b.
Figure 9.3
When the boiler functions in d.h.w. (Figure 9.4), the signal coming from the d.h.w. temperature probe is compared with the
signal given by the control panel through the adjustment made
by the user (key
).
12 Connector - 3way diverter valve
13 Connector - electric supply control panel p.c.b.
14 Connector - gas valve, pump and fan
9.3 Checking the temperature
The Main electronic control/ignition p.c.b. makes it possible to
separately adjust the c.h. water flow temperature and d.h.w.
outlet temperature.
The temperature of the water is converted into an electric signal
by means of temperature probes.
The user, setting the desired temperature with the control panel
p.c.b. key
or
.
If the power requested is lower than 40% of the maximum power
output then control is achieved by switching ON the burner at
minimum power, then switching OFF (ON/OFF function). If the
power requested is higher, then the burner is switched ON at
maximum power and will control by modulating to 40% of the
maximum power output.
During the c.h. operation (Figure 9.3), the signal coming from
the c.h. temperature probe is compared to the signal given by
the control panel through the adjustment made by the user (key
). The result of such a comparison operates the fan
speed thus regulating the gas flow rate and consequently changing the useful output of the boiler.
- 22 -
90 °C
Figure 9.4
MAIN Electronic control/ignition p.c.b.
Normally, the result of the comparison between these two signals
directly operates the fan speed adjusting the useful output generated in order to stabilize the temperature of the exiting water.
If during the d.h.w. mode operation, the temperature of the primary circuit goes over 90°C, the useful output is automatically
reduced so that the primary circuit cannot reach excessive temperatures.
The control sequences in function
and
illustrated in detail in sections 9.7 and 9.8.
in function are
D
E
9.4 Setting the boiler control function modes
It is possible to select the various boiler control function modes
hereafter named “parameters” by using the keys of the control
panel p.c.b.
Figure 9.7
3 To memorize the setting press the key B (Figure 9.8).
B
A
B
C
Figure 9.5
Figure 9.8
4 The setting is confirmed by the visualization of OK and then
the display shows the value of changed parameter (Figure
9.9).
1 To enter in the parameters setting mode press contemporary
the 3 keys (A - B - C Figure 9.5) for 10 seconds at the same
time until P01 are displayed on the display, indicating the entry in the “parameter 01” and the value of parameter (Figure
9.5 - Figure 9.6).
Figure 9.6
2 To change the parameters press c.h. set keys (D or E Figure
9.7) see also Tab 9.1.
Figure 9.9
5 To exit from setting without modifing the set press the
keys (A or C) till the visualization of parameter P 01 showing the lighting value before the setting (Figure 9.10).
- 23 -
MAIN Electronic control/ignition p.c.b.
Important: at the end of the setting operation it is important
to fill/update the table in the installation manual see chapter
COMMISSIONING section: Setting record.
A
C
PARAMETER
Boiler type (to be updated with the complete
range)
LCD
P 01
Type of water sensors
(C.h. / d.h.w.)
P 02
VALUES (SET)
00 = No power Er 99
35 = Activ A Plus 25C
36 = Activ A Plus 30C
37 = Activ A Plus 35C
40 = Activ A Plus 16S
41 = Activ A Plus 25S
00 =
01 =
Figure 9.10
02 =
6 In order to pass from a parameter to another press c.h. set
keys (A or C) at the same time until P 02 are displayed on
the display, indicating the entry in the “parameter 02” and the
value of parameter (Figure 9.11)
03 =
+
+
+
+
+
+
+
+
factory set
+
+
+
+
+
+
+
+
00 =
01 =
A
Pump speed
P 03
00 =
01 =
C
02 =
Zone valve setting
Room Thermostat /
Remote Control
P 04
Gas type
P 05
Not used
C.h. flow max
temperature °C
Factory parameters
reset
P 06
P 07
Figure 9.11
7 Repeat the previous steps in order to display the parameter’s
setting or to switch to the following
B
Figure 9.12
To reset the boiler to the normal operation press the key B (Figure
9.5) for 10 second or turn off the electricity supply to the boiler.
- 24 -
P 08
(2) Max
(1) Med
Self regulat.
00 = No (factory set)
01 = Z1 with R.T., Z2
with R.C., Max. c.h.
flow temperature
02 = Z1 with R.T., Z2
with R.C., Min. c.h.
flow temperature
00 = G20 Natural
01 = G25
02 = --- --- --- --03 = --- --- --- --04 = G30 Butane
05 = G31 Propane
85÷45 (factory set 85 °C)
00 = No reset
04 = All parameters
return to factory set
with the exclusion of
P 01 and P 05
39 = All parameters return
to factory set included Pr
01 and Pr 05
MAIN Electronic control/ignition p.c.b.
PARAMETER
LCD
Chimney sweep function P 09
C.h. reignition frequency P 10
C.h. pump post-circulation
Max. useful output in
c.h. mode
P 11
P 12
C.h. pump working type
P 13
Ignition power
P 14
Ignition power
P 14
K value (external probe
diagram)
P 15
Min. useful output c.h.
P 16
D.h.w. burner turn off
function
P 17
NTC on the c.h. return
P 18
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
C.h. minimum setpoint
Maintenance intervals
P 19
P 20
P 21
P 22
P 23
P 24
P 25
P 26
P 27
P 28
VALUES (SET)
PARAMETER
LCD
VALUES (SET)
00 = No chimney sweep
fun (factory set)
01 = D.h.w. low power
sweep---test
02 = C.h. low power
sweep---test
03 = C.h. max power
sweep---test
04 = D.h.w. max power
sweep---test
00÷99 (0÷600 sec.)
(factory set 30 = 3 minutes)
00÷99 (0÷600 sec.)
(factory set 10 = 1 minute)
00÷99 (0÷100%)
factory set according to
P 01
00 = Depends on room
thermostat (factory set)
04 = Always running
00÷99 (0÷100%)
factory set:
Natural gas (G20)
20 = Activ A Plus 25C
31 = Activ A Plus 30C
25 = Activ A Plus 35C
30 = Activ A Plus 16S
37 = Activ A Plus 25S
LPG Propane (G31)
26 = Activ A Plus 25C
37 = Activ A Plus 30C
31 = Activ A Plus 35C
36 = Activ A Plus 16S
43 = Activ A Plus 25S
00 = Off
(factory set)
01 (=0,1)÷60 (=6,0)
K value
00 ÷ 99 (0%÷100 %)
(factory set 00 = 0%)
00 = Burner off at fixed
d.h.w. = 65 °C
(factory set)
01 = Burner off at set
point +5 °C
00 = Probe not present
01 = Probe present
Presence of domestic
cold water temp.
probe or set of inlet cold
water with solar control
P 29
00 = No NTC probe
01 = Yes NTC probe
04 ÷ 45 (°C) temp.
NTC inlet probe with solar
control
05 (0,5 bar) ÷ 15 (1,5 bar)
factory set 10 (=1 bar)
Correct pressure c.h.
system
Tab 9.1
P 30
25÷45 (factory set 25 °C)
00 ÷ 48 (= months)
(factory set 12 months)
- 25 -
MAIN Electronic control/ignition p.c.b.
9.5 Checks
Check that the fuses are complete
If the Main electronic control/ignition p.c.b. does not supply any
device (pump, fan, etc.) check that the fuses 10 (Figure 9.2) are
complete.
If a fuse has blown replace it with one that has the same characteristics after having identified the reason for failure.
Lock sequence
Start the boiler until the burner is ignited.
With the burner firing, interrupt the gas supply. The Main electronic control/ignition p.c.b. must carry out four complete ignition
cycles and then, after about 4 minutes, goes to lock-out state.
Switch off and on the electricity supply to the boiler, by means of
the fused spur isolation switch, the device must not unlock and
the burner must not turn on.
9.6 Removal of the electronic control p.c.b
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
When replacing the Main electronic control/ignition p.c.b. all
parameters must be correctly checked / adjusted accordingly with the values noted in table in the installation manual
see chapter COMMISSIONING section: Setting record (for
information on parameters see also section 9.4).
1 Remove all the body panels (see section 2.2).
2 Gain access to the parts located inside the Main electronic
p.c.b. box as explained in the section 2.4 of this manual.
3 Remove all the wiring connected to the Main electronic control/ignition p.c.b.
4 Delicately flex the hooks F in the directions indicated (Figure
9.13) in order to release the circuit from the box.
5 Remove the Main electronic control/ignition p.c.b.
F
Figure 9.13
- 26 -
6 Re-assemble the Main electronic control/ignition p.c.b. following the removal procedures in the reverse order.
Important
When re-assembling the Main electronic control/ignition p.c.b.:
7 It is not necessary to utilise static protections but it is advisable to ensure that the pcb is handled with care and held at
the edges andwith clean dry hands.
Attention
After installing the Main electronic control/ignition p.c.b. properly
set the parameters.
Warning: After cleaning or replacement as detailed
above, it is deemed necessary to undertake a combustion analysis as detailed in section 11.3.
MAIN Electronic control/ignition p.c.b.
9.7 Thermal control in the
mode
Switch in the
Taking
water from the domestic hot
water circuit?
YES
circulator on
function mode
circulator off
fan still
NO
YES
YES
Is primary circuit
temperature higher than that
selected?
Main circuit pressure
switch consense?
YES
NO
stop circulator (3min)
NO
YES
NO
lock memorised?
cancels lock
starts fan
checks fan rpm
Is fan rpm
exact?
NO
YES
Is flue
temperature higher than 110°C?
NO
YES
beginning of wait period
flame presence?
End of wait
period?
YES
starts ignition discharges
Opens gas valve
beginning of ignition period
YES
NO
flame presence?
interrupts ignition discharges
gas valve open
fan runs
YES
NO
NO
End of ignition
period?
YES
closes gas valve
stops fan
interrupts ignition discharges
memorizes lock
display show lock--- out
NO
Is fan rpm
exact?
NO
NO
YES
safety thermostat or flue
temperature probe lock out?
YES
reset key
pressed?
flame presence?
YES
NO
YES
Figure 9.14
- 27 -
MAIN Electronic control/ignition p.c.b.
9.8 Thermal control in the
mode
Switch in the
See functioning with the function
control in the
mode
function mode
Taking
water from the domestic hot
water circuit?
YES
(sec. 9.7)
Request for heat from
room thermostat?
NO
circulator on
YES
Is primary circuit
temperature higher than that
selected?
circulator off
fan still
YES
Main circuit pressure
switch consense?
YES
NO
NO
stop circulator (3min)
NO
YES
NO
lock memorised?
cancels lock
starts fan
checks fan rpm
Is fan rpm
exact?
NO
YES
Is flue
temperature higher than 110°C?
NO
YES
beginning of wait period
flame presence?
End of wait
period?
YES
starts ignition discharges
Opens gas valve
beginning of ignition period
YES
NO
flame presence?
interrupts ignition discharges
gas valve open
fan runs
YES
NO
NO
End of ignition
period?
YES
closes gas valve
stops fan
interrupts ignition discharges
memorizes lock
display show lock--- out
NO
Is fan rpm
exact?
NO
NO
YES
safety thermostat or flue
temperature probe lock out?
YES
Figure 9.15
- 28 -
YES
reset key
pressed?
flame presence?
YES
NO
Control panel electronic p.c.b.
10 Control panel electronic p.c.b.
10.1Function
F
J
A
E
B
D
H
C
G
I
Figure 10.1
A
B
C
D
E
F
G
H
I
J
C.h. temperature increase key
C.h. temperature reduce key
Reset/Stand-by/Winter/Summer key
D.h.w. temperature reduce key
D.h.w. temperature increase key
Display
3 star preheating function key
Reset Key
Access to function menu key
Clock key: used to access the clock functions (Time/Day/
Date setting) and the timer (3 star preheating function and
heating flow timer)
The Control panel electronic p.c.b. can give to the service 3 levels of informations:
• Normally information
• Info modality
• Function modes setting modality
10.2Normaly information
KEY
All symbols represented with lines that
surround them, indicate that the symbol
is flashing
Constantly illuminated: chimney sweep
function enabled
Constantly illuminated: the presence of
this symbol during normal operation indicates that the heating or preheating timer
has been set.
Flashing: this indicates that the clock has
not yet been set by the user.
Indicate the status of the scheduling request
Flashing:
comfort program in process;
reduced program in process;
The day of the week is displayed highlighting the number with the following
sequence: 1=Mon… 7=Sun
Constantly illuminated: d.h.w function
enabled
Flashing: d.h.w function enabled
Flashing:
solar circuit pump in operation
Solar integration at the time of d.h.w
withdrawal is indicated by the lighting of
the bars.
SV versions: the bars indicate the value
of the temperature of the solar storage
(range 40...80°C)
Constantly illuminated: heating request
from zone 1 and/or zone 2
Flashing: heating function in progress
Constantly illuminated: delivery probe
and/or return probe
The ignition of the key, the arrow, M, and
the month (1 or 2) indicates the next due
date for maintenance.
The flashing of the symbol, the arrow, M
and 0 indicates that the maintenance period has expired
Temperature measurement unit
Constantly illuminated: 3 star preheating
function active
Flashing: 3 star preheating function in
process
Flashing: down (before flame detection)
Constantly illuminated: flame present and
modulation level
Constantly illuminated: lockout error. The
boiler can be restarted by the user by
pressing the reset button
Non resettable error
The back lighting has to be flashing
Constantly illuminated: set value
Constantly illuminated: temperature is displayed without decimals but with a sign
(probe connected)
Indicated boiler pressure
Constantly illuminated: boiler power delayed by inhibitor (AFCT) or other events
Constantly illuminated: remote control
connected
Flashing: request from remote control in
process
INFO menu input enabled
Constantly illuminated: pump active
The icon remains on for post-circulation
- 29 -
Control panel electronic p.c.b.
Constantly illuminated: boiler antifreeze
active
Antifrostat
Constantly illuminated: (system antifreeze active
SIGNAL DISPLAYED BY THE LCD
LCD
FUNCTION
E01 +
Lack of burner ignition on safety lockout
E02 +
Safety thermostat intervention lockout
E03 +
General lockout
E04 +
Little pressure in the system or pressure
transducer disconnected
E05 +
Pressure switch anomaly (if present)
E06 +
Faulty c.h. temp. probe NTC1 or NTC2
E07 +
Faulty d.h.w. temp. probe NTC
E08 +
Faulty external temp. probe NTC (with K set)
E09 +
Faulty flue temp. probe NTC (if present)
E10 +
Flue probe intervention lockout (if present)
E11 +
Flame detection error
E12 +
Failure return NTC probe
E13 +
DT delivery-return > 40K (if foreseen)
E14 +
Faulty pump or primary temperature above
105°C
E14 +
Absence of flow from temperature gradient
(>2K/s)
E20 +
Lockout EVG
E21 +
Lockout EVG
E22 +
Lockout EVG
E23 +
Lockout EVG
E24 +
Abnormal combustion ignition lock
E25 +
Abnormal combustion operation lock
E69 +
Wiring error lockout
E99 +
Boiler not configured
L 01
- 30 -
Primary circuit temp. limit during D.h.w. operation
Boiler Stand-By, hyphens are turned on in
sequence to simulate running (antifreeze
protection activated)
LCD
FUNCTION
In the case of incorrect pressure the value is
visualised with a flashing symbol
When pressure is achieved the symbol remains on for 15 s and then disappears.
Flashing:
high pressure > 2.8 bar ON, 2.6 bar OFF;
intermediate pressure
0.15 < P < Pon rising
0.15 < P < (Pon-0.2) decreasing;
pressure critical
0.00 < P < 0.15 bar
Pump activated for the post-circulation phase (Po flashing + temperature flashing)
Boiler in anti-freeze phase (bP flashing +
temperature flashing)
Boiler on demand for d.h.w. power.
The d.h.w. temperature is displayed.
Boiler requesting heating power and remote
control connected.
Set c.h.
(all other symbols are disabled)
Set D.h.w.
(all other symbols are disabled)
Delayed burner ignition for setting the system (the hourglass symbol turns on)
Boiler in chimney sweep in function.
The activation of the chimney sweep occurs
configuring the "parameter P09=01" and is
visualized:
LP= minimum dhw
hP= minimum heating
cP= maximum heating
dP= maximum dhw
The transition occurs with keys A (increase)
and B (decrease) dhw temperature.
The writing on the display alternates.
Control panel electronic p.c.b.
10.3Info modality
The INFO mode allows the display of some information on the
boiler functioning status. In case ofmalfunctioning of the boiler,
it may be useful to communicate such information to the Authorised Service Centre Engineer so that the causes can be understood.
In order to access the INFO mode, press keys A (Figure 10.1) the
index J00 and the value of the parameter appear on the display
(Figure 10.2).
10.4Function modes setting modality
It is possible to select the various boiler control function modes
hereafter named “parameters” by using the keys of the control
panel p.c.b.
During the function modes setting, the boiler does not operate.
To get in function modes setting modality see section 9.4
10.5Removal of the control panel electronic
p.c.b
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
Figure 10.2
To scroll the values press B (reduce) and A (increase). keys (Figure 10.1). In order to exit the INFO mode, hold keys A and C
(Figure 10.1) pressed at the same time. The following table gives
details of each parameter and the possible value that can be
show.
Value visualised
1 Remove all the body panels (see section 2.2).
2 Gain access to the parts located inside the Control panel electronic p.c.b. as explained in the section 2.3 of this manual.
3 Remove all the wiring M connected to the Control panel electronic p.c.b. (Figure 10.3).
Index
Primary circuit pressure
J00 + value
External temperature
J01 + value
K curve value configured in loco
J02 + value
Offset climatic curve value
J03 + value
Calculated heating set point (with climatic curve
or set configured)
J04 + value
Temperature NTC delivery
J05 + value
Temperature NTC return
J06 + value
Domestic set
J07 + value
Temp. Dhw inlet (if foreseen)
J08 + value
Temp. Dhw output
J09 + value
Dhw capacity
J10 + value
K
Flue temperature (if foreseen)
J11 + value
Fan speed (if foreseen)
J12 + value
Pressure transducer pressure (if foreseen)
J13 + value
Ionization value
J14 + value
Number of months to maintenance
J15 + value
3 star status
(ON=01, OFF=00)
J16 + value
HWCH Hardware code high
J17 + value
HWCL Hardware code low
J18 + value
5 Remove the Control panel electronic p.c.b.
SWCH Software code high
J19 + value
SWCL Software code low
J20 + value
6 Reassemble the Control panel electronic p.c.b. carrying out
the removal operations in the reverse order.
M
L
Figure 10.3
4 Unscrew the screws L and K.
10.6Removal of the interface electronic p.c.b
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
- 31 -
Control panel electronic p.c.b.
1 Remove all the body panels (see section 2.2).
2 Gain access to the parts located inside the Interface electronic p.c.b. as explained in the section 2.3 of this manual.
3 Remove all the wiring N, S, O e P connected to the Interface
electronic p.c.b. (Figure 10.4).
Q
N
P
R
S
O
Figure 10.4
4 Unscrew the screws R and Q.
5 Remove the Interface electronic p.c.b.
6 Reassemble the Interface electronic p.c.b. carrying out the
removal operations in the reverse order.
- 32 -
gas valve
11 gas valve
11.3Adjustment
11.1Function
The gas valve A in Figure 11.1 controls the gas inflow to the boiler
burner.
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
Check the supply pressure before making any adjustment
to the gas valve.
1 Close the gas inlet valve.
2 Remove the front panel of the case and lower the control panel
(see sections 2.2 and 2.3).
3 Loosen the internal screw on the Inlet Pressure Test Point F
(Figure 11.2) of the Gas valve and connect a pressure gauge
using a suitable hose.
4 Open the gas inlet valve.
5 Turn on the electricity supply to the boiler, switching on the
fused spur isolation switch.
6 Set the boiler in c.h. / d.h.w. function as illustrated in Figure
11.3.
A
C.h. / d.h.w. function
Figure 11.1
By means of an electric command given to the on-off operators
the passage of the gas through the Gas valve can be opened or
closed.
Figure 11.3
7 Open at least one hot water tap fully.
8 Read the inlet pressure value and ensure that it is within the
limits given in the table Gas supply pressures, of the user/
installation manual. If it does not comply with the required
pressure check the gas supply line and governor for faults
and/or correct adjustment.
11.2Description of the parts - (Figure 11.2)
B
C
D
E
F
Maximum gas pressure adjustment
Minimum gas pressure adjustment
On-off operators
On-off operators electric connector
Gas valve inlet pressure test point
9 Switch off the boiler close the gas inlet valve and close the
water tap.
10 Disconnect the pressure gauge and close the Inlet Pressure
Test Point F (Figure 11.2).
Gas valve adjustment
The person carrying out a combustion measurement
should have been assessed as competent in the use of
a flue gas analyser and the interpretation of the results. The flue gas analyser used should be one meeting the requirements of BS7927 or BS-EN50379-3 and
be calibrated in accordance with the analyser manufacturers’ requirements, and have a current calibration
certificate.
B
C
D
11 Fit the probe of the flue analyser in the flue exhaust sampling
point located on the exhaust pipes of the boiler (Figure 11.4).
flue
exhaust
sampling point
E
F
air intake
sampling point
Figure 11.2
Figure 11.4
- 33 -
gas valve
12 Turn on the boiler, switching on the fused spur isolation
switch.
13 Open the gas inlet valve.
14 Turn on the boiler and operate for 2 minuets to pre-heat the
flue, before commencing any adjustments
G
H
To adjust the CO2 % value remove the brass plug by unscrewing
it and rotate the Allen key screw ø 4mm (C - Figure 11.2) (by
rotating it clockwise the CO2 % increases).
Checking the minimum gas valve setting in heating mode
19 Press key G to vary the output in chimney sweep mode: when
the display shows the letters hP that alternate with the heating water temperature value (e.g. 32), the ”chimney sweep
function” is at minimum power during heating (Figure 11.9);
I
Figure 11.5
15 To enter in the parameters setting mode press contemporary
the 3 keys (G - H - I Figure 11.5) for 10 second until the display shows Figure 11.6.
Figure 11.8
20 Allow the analyser to give a stable reading.
Figure 11.6
21 Read the CO2 % value. It should be between:
Model
Checking the minimum gas valve setting in domestic hot
water mode
16 Press keys G and H (Figure 11.5) at the same time until the
display shows the letters LP that alternate with the heating
water temperature value (e.g. 45), indicating the activation of
the ”chimney sweep function” at minimum output (Figure 11.7).
Activ A Plus 30C
Activ A Plus 35C
Activ A Plus 16S
Activ A Plus 25S
Type gas
Natural (G20)
CO2 % value (range)
8,7 - 9,3
Propane (G31)
9,4 - 10,4
Natural (G20)
8,7 - 9,3
Propane (G31)
9,4 - 10,4
To adjust the CO2 % value remove the brass plug by unscrewing
it and rotate the Allen key screw ø 4mm (C - Figure 11.2) (by
rotating it clockwise the CO2 % increases).
Checking the maximum gas valve setting in heating mode
22 Press key G to vary the output in chimney sweep mode: when
the display shows the letters cP that alternate with the heating water temperature value (e.g. 78), the ”chimney sweep
function” is at maximum output in heating mode (Figure 11.9);
Figure 11.7
17 Allow the analyser to give a stable reading.
18 Read the CO2 % value. It should be between:
Model
Activ A Plus 30C
Activ A Plus 35C
Activ A Plus 16S
Activ A Plus 25S
Type gas
Natural (G20)
CO2 % value (range)
8,7 - 9,3
Propane (G31)
9,4 - 10,4
Natural (G20)
-
Propane (G31)
Figure 11.9
- 34 -
gas valve
23 Allow the analyser to give a stable reading.
24 Read the CO2 % value. It should be between:
Model
Activ A Plus 30C
Activ A Plus 35C
Type gas
Natural (G20)
CO2 % value (range)
9,2 - 9,8
Propane (G31)
9,9 - 10,8
Activ A Plus 16S
Activ A Plus 25S
Natural (G20)
9,2 - 9,8
Propane (G31)
9,9 - 10,8
29 Press keys G - H - I (Figure 11.5) at the same time again to
exit the ”chimney sweep mode” and return to the previously
set boiler status (Figure 11.11)
C.h. / d.h.w. function
To adjust the CO2 % value rotate screw (B - Figure 11.2) (by rotating it clockwise the CO2 % decreases).
Figure 11.11
Checking the maximum gas valve setting in domestic hot
water mode
25 Press further key G to vary again the output in chimney
sweep mode: when the display shows the letters dP that alternate with the heating water temperature value (e.g.60), the
”chimney sweep function” is at maximum output in domestic
hot water mode” (Figure 11.10);
30 Switch off the boiler and turn off the hot water tap(s).
31 Close the air-flue sampling points.
32 After adjustment fit the protective brass plug (C - Figure 11.2).
Important: after the gas pressure checks and any adjustment
operations, all of the test points must be sealed.
11.4Checks
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
Check the on-off operators coils
1 Remove the front panel of the case.
2 Disconnect the electrical connector E (Figure 11.2).
3 Measure the electrical resistance between the connector pins
of the on-off operators as illustrated in Figure 11.12.
Upper on-off operator
approx. 6400 Ω*
Figure 11.10
Lower on-off operator
approx. 920 Ω*
26 Open at least one hot water tap fully.
27 Allow the analyser to give a stable reading.
*at ambient temperature.
28 Read the CO2 % value. It should be between:
Model
Activ A Plus 30C
Activ A Plus 35C
Activ A Plus 16S
Activ A Plus 25S
Type gas
Natural (G20)
CO2 % value (range)
9,2 - 9,8
Propane (G31)
9,9 - 10,8
Natural (G20)
9,3 - 9,9
Propane (G31)
10,0 - 10,9
Natural (G20)
-
Propane (G31)
-
Figure 11.12
To adjust the CO2 % value rotate screw (B - Figure 11.2) (by rotating it clockwise the CO2 % decreases).
- 35 -
gas valve
11.5Removal of the gas valve
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove the front panel of the case as explained in the section 2.3, of this manual.
8 Remove the brass plug and turn the plastic screw inside it
fully clockwise until it stops. Do not overtight.
9 Turn it counter-clockwise 2 and 3/4 turns.
10 Adjust the gas valve using the flue analyser as described in
section 11.3.
2 Disconnect the connector J (Figure 11.13).
O
After any service operation on the components of the gas
circuit check all the connections for gas leaks.
Warning: After cleaning or replacement as detailed
above, it is deemed necessary to undertake a combustion analysis as detailed in section 11.3.
P
N
L
M
J
K
Figure 11.13
3 Turn off the gas supply and disconnect the gas isolation cock
connector from the inlet port of the gas valve.
4 Using pliers, remove the spring L and the rubber pipe M (Figure 11.13).
5 Unscrew the connector N, remove the fixing fork O and remove the pipe P.
6 Unscrew the screws K and remove the valve.
7 Reassemble the valve carrying out the removal operations in
reverse order.
Warning: Be careful not to damage the OR gasket of
the gas pipe when inserting the pipe in the air box
(air/gas mixer).
Before fitting a new valve, it is advisable to preset it as follows.
- 36 -
Primary circuit flow switch
12 Primary circuit flow switch
12.1Function
The Primary circuit flow switch (A in Figure 12.1) function is to
check the presence of water in the primary hydraulic circuit and
that the pressure is above the minimum.
12.3Removal
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove the front and right hand side panels of the case, turn
off the flow and return isolation valves and empty the primary
circuit.
2 Remove the fixing spring D (Figure 12.3) and remove the primary circuit pressure switch C.
3 Disconnect the connectors E (Figure 12.3).
E
A
C
D
B
Figure 12.1
Figure 12.3
This device is connected to the main electronic control p.c.b. and if,
it does not activate the control board will indicate that a fault condition (see section 4.1 of this manual) has occurred.
4 Reassemble the primary circuit pressure switch in reverse
order of removal.
12.2Checks
Warning: to lubricate the O-ring gaskets exclusively
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
use a silicone base grease compatible to be in contact
with foods and approved by the local water Authorities.
Electrical check
It is possible to verify the general operation of the switch by measuring the electric resistance between the contacts "bk" and "wh"
of the switch.
1 Measure the electrical resistance between the tabs "bk" and
"wh" (Figure 12.2).
The contact must close (resistance zero) with c.h. pressure of
0,35 bar or higher.
rd
5V
bk
wh
wh
rd
bk
The contact close
(resistance zero)
with c.h. pressure of
0,35 bar or higher.
wh = white
bk = black
rd = red
Figure 12.2
- 37 -
Expansion vessel and pressure gauge
13 Expansion vessel and pressure
gauge
13.1Function
The Expansion vessel (A in Figure 13.1 function is to allow for the
volume expansion of the c.h. circuit water due to the temperature
rise.
13.3Removal of the expansion vessel
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove the front and right hand side panels of the case, turn
off the flow and return isolation valves and empty the primary
circuit.
2 Completely unscrew the connection C, the locknut D (Figure
13.3).
3 Unscrew the screws E and remove the bracket F (Figure
13.3).
4 Remove the expansion vessel from the front of the boiler.
5 Re-assemble the parts in reverse order of removal.
E
F
A
Figure 13.1
13.2Checks
1 Turn off the flow and return isolation valves and empty the
primary circuit of the boiler.
2 Remove the protective cap B in Figure 13.2 from the valve
on the top of the expansion vessel and connect a suitable air
pressure gauge.
B
Figure 13.2
3 Check the pre-load pressure and refer to the section Expansion vessel in the User manual and installation instructions
for the correct value.
D
C
Figure 13.3
- 38 -
D.h.w. flow switch, filter and flow limiter
14 D.h.w. flow switch, filter and flow
limiter
14.1Function
The d.h.w. flow switch A in Figure 14.1 is a device that generates
an electrical signal when hot water is drawn.
14.3Removal of the sensor
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
E
D
B
C
A
Figure 14.3
1 Remove the front panel of the case.
2 Disconnect the connectors B and remove the sensor holder
C (Figure 14.3).
Figure 14.1
When the flow rate through the d.h.w. circuit reaches about 2,5
litres/min’, the sensor closes the electric contact that switches
the boiler d.h.w operation ON.
14.2Description and location of parts - (Figure
14.2)
1
2
3
4
5
Flow switch plug
O-ring
Flow limiter (Activ A 30C. Activ A 35C. optional accessory)
Body with flow meter turbine
Filter
1
3 Remove the sensor.
14.4Checks
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
Sensor operation
0..32 Hz
(without flow rate)
wh
bu
rd
33..200 Hz
(witht flow rate)
5V
B
5
rd
bu
2
3
4
2
wh = white
bu = blue
rd = red
wh
Figure 14.2
Figure 14.4
1 Remove the front panel of the case.
2 Don't disconnect the connectors B
3 Measure the electrical frequency at the leads of the sensor.
Without flow rate the electrical frequency must be 0÷32Hz.
With flow rate the electrical frequency must be 33÷200Hz.
- 39 -
D.h.w. flow switch, filter and flow limiter
14.5Removal of the flow switch group and d.h.w.
circuit filter
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove the front panel of the case and empty the d.h.w. circuit.
2 Remove the fork D and pull up the flow switch plug E (Figure
14.3) with the help of a screwdriver.
3 To remove the body 4 with the filter from the flow switch group
rotate the flow switch plug 1 (Figure 14.5).
4 Reassemble the parts following the removing sequence in
reverse order.
14.6Flow limiter
The Activ A 25C model is factory fitted with a 10 litres/min. flow
limiter (white).
To install the flow limiter:
1 Remove the flow switch group as explained in the section
14.5.
2 Rotate the flow switch plug 1 to separate it from the body 4
(Figure 14.5).
rotate
insert
1
3
4
Figure 14.5
3 Insert the flow limiter 3 as shown in Figure 14.5.
4 Reassemble the group following the above sequence in reverse order.
- 40 -
Temperature probe
15 TEMPERATURE PROBE
15.2Checks
15.1Function
The Temperature probe has the function of converting the temperature of the water in the hydraulic circuit where it is installed into
an electrical signal (resistance).
The relation between temperature and electrical resistance is
stated in Figure 15.1.
Ω
12500
12000
11500
11000
10500
10000
9500
9000
8500
8000
7500
7000
6500
6000
5500
5000
4500
4000
3500
3000
2500
2000
1500
1000
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Figure 15.1
Temperature-resistance relationship
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
Disconnect the cable from the Temperature probe.
Measure the temperature of the pipes F and H (only c.h. Temperature probe) where the Temperature probes are located and
check the electrical resistance according to the graph in Figure
15.1.
15.3Removal of the c.h. Temperature probes
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove all the case panels and the sealed chamber lid.
2 Empty the primary circuit of the boiler.
3 Remove the electric connector G and E and unscrew the c.h.
Temperature probes A and B (Figure 15.3).
°C
4 Reassemble the c.h.Temperature probes carrying out the removal operations in reverse order.
On the boiler there are four Temperature probes. Two on the input/output of the primary condensing heat exchanger (c.h. Temperature probe) A and B in Figure 15.2 and Figure 15.3; two on
the input/output of the d.h.w. heat exchanger (d.h.w. Temperature probe) C and D in Figure 15.2, Figure 15.4 and Figure 15.5.
H
F
A
B
B
A
G
E
D
Figure 15.3
C
c.h.
return
c.h.
flow
d.h.w.
inlet
d.h.w.
outlet
Figure 15.2
- 41 -
Temperature probe
15.4Removal of the d.h.w. Temperature probes
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
Removal of the d.h.w. Outlet Temperature probe
Removal of the d.h.w. Intlet Temperature probe
1 Remove the front panel of the case and lower the control
panel.
6 Remove the front panel of the case and lower the control
panel.
2 Empty the d.h.w circuit of the boiler.
7 Empty the d.h.w circuit of the boiler.
3 Remove the electric connector I (Figure 15.4)
8 Remove the electric connector K (Figure 15.5)
4 Remove the fork J and pull the d.h.w. Temperature probe C.
9 Remove the fork L and pull the d.h.w. Temperature probe D.
5 Reassemble the d.h.w. Temperature probe carrying out the
removal operations in reverse order.
10 Reassemble the d.h.w. Temperature probe carrying out the
removal operations in reverse order.
Warning: to lubricate the O-ring gaskets exclusively
Warning: to lubricate the O-ring gaskets exclusively
use a silicone base grease compatible to be in contact with foods and approved by the local water Authorities.
use a silicone base grease compatible to be in contact with foods and approved by the local water Authorities.
L
D
K
J
C
Figure 15.4
- 42 -
I
Figure 15.5
By-pass valve
16 By-pass valve
16.2Removal
16.1Function
The By-pass valve A in Figure 16.1 is located between the c.h.
water flow and return and its function is that of guaranteeing a
minimum flow across the primary heat exchanger if the circulation across the c.h. system is completely closed.
The By-pass valve is fitted on the rear side of the diverter
group.
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove all the case panels.
2 Empty the primary circuit of the boiler.
3 Remove the locking plate B and pull up the by-pass valve A
(Figure 16.2).
A
A
B
Figure 16.2
4 Reassemble the by-pass valve as illustrated in Figure 16.2
reversing the order of removal.
Figure 16.1
Warning: to lubricate the O-ring gaskets exclusively
use a silicone base grease compatible to be in contact with foods and approved by the local water Authorities.
Attention. When reassembling the By-pass valve be sure
that it is correctly oriented by matching the reference C with
the notch D of the water group Figure 16.3
A
C
D
Figure 16.3
- 43 -
Fan and Air box
3 Disconnect the air manifold C (Figure 17.2).
17 Fan and Air box
4 Disconnect the rubber pipe D.
5 Unscrew the gas connector E.
17.1Function
The function of the Fan A (Figure 17.1) is to force the mixture of
air and gas into the burner.
The function of the Air box B is to mix the gas and the air in the
right proportion.
The flow rate of the air-gas mixture and consequently the input
power of the boiler is proportional to the speed of the fan that is
controlled by the electronic control p.c.b.
6 Remove the fixing fork F and remove the gas pipe G.
7 Disconnect the connector H
8 Disconnect the fan connector I by pressing the plastic hook
placed on the side of the connector.
9 Unscrew the screws J.
10 Remove the fan A with the air box B.
11 Remove the screws K and the air box B (Figure 17.3).
K
K
B
B
A
K
Figure 17.3
12 Assemble the Fan and the Air box carrying out the removal
operations in reverse sequence.
Figure 17.1
Before reassembling ensure the fan gasket (Figure 17.2) is
correctly mounted.
17.2Removal of the Air box and the Fan
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
Warning: Be careful not to damage the OR gasket of
the gas pipe when inserting the pipe in the air box
(air/gas mixer).
1 Turn off the gas supply.
After any service operation on the components of the gas
circuit check all the connections for gas leaks.
2 Remove all the case panels (see section 2).
C
Warning: After cleaning or replacement as detailed
above, it is deemed necessary to undertake a combustion analysis as detailed in section 11.3.
J
H
I
F
D
B
G
A
E
Figure 17.2
- 44 -
Ignition and detection electrodes
18 Ignition, detection electrodes
and burner
18.1Function
Three electrodes are fitted on the fan-burner group.
Two of them, fitted on the right side of the fan-burner group A, are
the ignition electrodes B.
On the left side is the detection electrode C and it detects the
presence of the flame.
18.2Removal of the Ignition and detection electrodes
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove all the case panels (see section 2).
2 Disconnect the ignition electrodes connector D and the earth
wire E (Figure 18.1) and disconnect the detection electrode
connector F.
3 Unscrew the screws G and remove the ignition electrodes B
and the detection electrode C.
A
4 Assemble the Ignition and detection electrodes carrying out
the removal operation in reverse order.
I
H
G
C
B
G
18.3Removal of the burner
E
I
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove the air box and the fan (see section "Removal of the
Air box and the Fan" page 44)
I
2 Remove the Ignition and detection electrodes (see section
"Removal of the Ignition and detection electrodes" page 45).
3 Unscrew the screws H (Figure 18.1) and remove the cover of
the combustion chamber.
4 Unscrew the screws I (Figure 18.1) and remove the Air-gas
duct lid.
D
F
5 Remove the burner by sliding it forward.
Figure 18.1
The burner J is fitted on the rear of the fan-burner group A.
burner gasket
J
Figure 18.2
locating tab
Figure 18.3
6 Assemble the burner carrying out the removal operation in
reverse order. Ensure the burner is correctly located by lining
up the locating tab (Figure 18.3).
- 45 -
Ignition and detection electrodes
burner gasket
Air--- gas duct gasket
18.5Removal of the rear insulation
See warning note at the end of this chapter before to remove
this part.
Attention: Cover the inner of the condensing heat
exchanger to avoid that dirt and debris fall in the
coil.
1 Do the operations of section "Removal of the burner" page 45
from step 1 to step 3.
2 Unscrew the screw K, remove the washer L and the rear insulation M (Figure 18.6).
Figure 18.4
Before reassembling ensure the burner gasket is correctly
located.
Warning: After cleaning or replacement as detailed above, it is deemed necessary to undertake a combustion
analysis as detailed in section "Adjustment" page 33.
M
K
18.4Removal of the front insulation panel
L
See warning note at the end of this chapter before to remove
this part.
1 Remove the Ignition and detection electrodes (see section
"Removal of the Ignition and detection electrodes" page 45).
2 Remove the burner (see section "Removal of the burner"
page 45).
Figure 18.6
3 Remove the front insulation panel (Figure 18.5).
4 Assemble the new front insulation carrying out the removal
operation in reverse order. When fitting the new panel ensure
that the electrodes holes coincide with the holes of the combustion chamber.
18.6Checks
Check of the spark generator
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
There is not a significant way to verify the integrity of the spark
generator. When the fan turns but the burner does not light a
possible cause is a faulty spark generator and it is advisable to
replace it to locate the fault.
Check the position of the electrode edges
front insulation
Siliconic gasket
Figure 18.5
Caution:
After any periodical servicing or disturbance the combustion
chamber silicon seal (Figure 18.5) must be fully inspected and
replaced at the discretion of the service engineer.
After any disturbance to the chamber door seal the appliance
must undergo a full analytical combustion performance check.
- 46 -
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove the ignition electrodes (see section "Removal of the
Ignition and detection electrodes" page 45)
2 Check for the correct distance between the metallic edges of
the ignition electrode (see Figure 18.7 - Figure 18.8).
Ignition and detection electrodes
3,5 mm
earth electrode
High dust levels are only likely to arise following harsh abrasion.
In general, normal handling and use will not present high risk, follow good hygiene practices, wash hands before, touching eyes,
consuming food, drinking or using the toilet.
First aid - Medical attention must be sought following eye contact
or prolonged reddening of the skin.
Ignition electrode
Figure 18.7
Check the connection wires
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
7 mm
Ignition electrode
Figure 18.8
1 Remove all the case panels and the sealed chamber lid.
2 Check for the integrity of the insulation of wires which connect the electrodes to the spark generator and to the control/
ignition p.c.b.
Warning - Insulation panelsmaterial handling care
Mineral fibres are used in this appliance for the insulation panels
of the combustion chamber
Excessive exposure to thesematerials may cause temporary irritation to eyes, skin and respiratory tract.
Known hazards - Some people can suffer reddening and itching
of the skin. Fibre entry into the eye will cause foreign body irritation, which can cause severe irritation to people wearing contact
lenses. Irritation to respiratory tract.
Precautions - Dust goggles will protect eyes. People with a history of skin complaints may be particularly susceptible to irritation.
- 47 -
Safety thermostat
19 Safety thermostat
19.1Function
The safety thermostat A in Figure 19.1 is a device that senses
the temperature of the primary circuit water which flows in the
outlet pipe of the condensing heat exchanger.
If the temperature control system of the boiler fails and the temperature of the primary circuit reaches a dangerous temperature,
the safety thermostat opens the electric circuit that supplies the
on-off operators of the gas valve.
Consequently, the full sequence ignition device attempts to light
the burner and, at the end, locks the boiler and lights the lock-out
on the display.
19.3Removal
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove all the case panels.
2 Disconnect the wiring B (detail in Figure 19.2).
3 Unscrew the screws C and remove the overheat thermostat.
A
C
B
Figure 19.2
4 Reassemble the overheat thermostat carrying out the operations in reverse order.
5 Apply an adequate quantity of heat conducting compound
between the pipe and the thermostat.
Figure 19.1
19.2Checks
Overheat temperature value
1 Run the boiler and set the temperature at maximum by pressing the appropriate key.
2 Allow the boiler to reach its maximum operating temperature
(monitor the temperature gauge on the instrument panel).
The boiler shouldmaintain a temperature below that of the
safety thermostat and no overheat intervention should occur.
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
Electrical function
1 Remove all the case panels and the lid of the sealed chamber.
2 Disconnect the safety thermostat and check its electrical function. Normally (no intervention) the contact must be closed
(electrical resistance zero Ω).
- 48 -
Warning: After cleaning or replacement as detailed
above, if it deemed necessary to undertake a combustion analysis as detailed in section 11.3.
Flue temperature probe NTC and Safety thermal fuse
20 Flue temperature probe NTC and
Safety thermal fuse
20.1Function
Reaching the breakdown temperature it opens the circuit and
locks out the boiler.
In case of intervention of this safety device the heat exchanger (part
shown in Figure 20.3) may be damaged and must be replaced.
The Flue temperature probe NTC A in Figure 20.1 and Figure
20.2 senses the temperature of the combustion products that
flow through the condensing heat exchanger.
B
A
Figure 20.3
20.2Removal
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove all the case panels.
Figure 20.1
If the temperature of the combustion products circuit reaches the
limit temperature, the Flue temperature probe NTC reduces the
gas flow rate to the burner. The temperature of the combustion
products should decrease to a safe value temperature.
In the case that the temperature of the combustion products reaches a potentially dangerous value, it stops the boiler operation
(lock-out).
This allows the use of plasticmaterials for the flue outlet pipes
and bends.
The use of kits different from the original isn’t however allowed,
since the flue pipes are integral parts of the boiler.
2 Disconnect the connector C from the Flue temperature probe
NTC by pressing the plastic hook placed on the side of the
connector.
3 Unscrew and remove the flue temperature probe A (Figure
20.2) from the condensing heat exchanger.
4 Assemble the Flue temperature probe NTCcarrying out the
removal operations in reverse sequence.
20.3Checks
Overheat temperature value
1 Set the temperature control knobs to their max. position and
run the boiler in d.h.w. and c.h.
B
C
A
2 Allow the boiler to reach its maximum operating temperature
(monitor the temperature gauge on the instrument panel).
The boiler shouldmaintain a temperature below that of the
Flue temperature probe NTC and no overheat intervention
should occur.
Temperature-resistance relationship.
Figure 20.2
A Safety thermal fuse B in Figure 20.1 - Figure 20.2 is also connected in series with the Flue temperature probe NTC and acts
as a safety device in extreme case of incorrect operation of the
Flue temperature control system.
1 Remove the Flue temperature probe NTC(see section 20.2).
2 Measure the Flue temperature probe NTC electrical resistance at the ambient temperature and check it according to the
graph in (Figure 20.4)
- 49 -
Flue temperature probe NTC and Safety thermal fuse
Ω 12500
12000
11500
11000
10500
10000
9500
9000
8500
8000
7500
7000
6500
6000
5500
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
20 25 30
Figure 20.4
- 50 -
35 40
45 50
55 60 65
70 75
80 85
90 95 100
°C
Condensate trap
21 Condensate trap
21.1Function
The condensate trap A in Figure 21.1 and Figure 21.2 allows
the discharge of the condensate via the condensate drain pipe
avoiding in the mean time the escape of combustion products.
A plastic ball closes the trap outlet in case that the trap is empty.
21.3Removal
Warning: isolate the boiler from the mains electricity supply before removing any covering or component.
1 Remove the front and right case panels.
2 Unscrew the threaded locking ring B and remove the flexible
pipe C (Figure 21.2).
3 Using pliers, remove the spring D moving it upwards.
4 Unscrew the screw E and remove the trap A from the pipe F.
5 Reassemble carrying out the removal operations in reverse
order.
F
D
A
Figure 21.1
A
E
If the drain pipe becomes blocked, or condensate cannot
drain, the condensate level it the trap rises until it reaches
the screw attached to the flame detection electrode,
this will cause the boiler lock-out..
B
21.2Check the cleanness of the trap
Unscrew the plug B on the bottom of the trap A and remove dirt
eventually deposit (Figure 21.2).
C
Figure 21.2
- 51 -
Short spare parts list
22 Short spare parts list
Key G.C. part no. Description
Q.ty
1
1
1
1
1
Manufacturer
part no.
BI1313 100
BI1313 101
BI1462 100
BI1432 101
1
BI1432 100
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
3
2
1
1
BI1313 102
BI1313 103
BI1181 100
BI1131 100
BI2035 100
2
3
H58-660
H58-659
4
5
6
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
- 52 -
H50-189
E83-013
E01-205
H74-553
H20-989
E83-101
H58-661
E23-792
169-016
H58-709
H58-709
Burner (mod. Activ A Plus 25S, Activ A Plus 16S)
Burner (mod. Activ A Plus 30C, Activ A Plus 35C)
Expansion vessel
Condensing heat exchanger
(mod. Activ A Plus 30C, Activ A Plus 35C )
Condensing heat exchanger
(mod. Activ A Plus 25S, Activ A Plus 16S)
Fan
Gas valve
Safety valve (mod. Activ A Plus 30C, Activ A Plus 35C)
Safety valve (mod. Activ A Plus 25S, Activ A Plus 16S)
Main Electronic control/ignition p.c.b.
Interface electronic p.c.b.
Control panel electronic p.c.b.
D.h.w. heat exchanger
Pump
Temperature probe (main circuit)
D.h.w. flow switch
D.h.w. flow sensor
Primary circuit pressure switch
Three way diverter valve (electric actuator)
Condensate trap
Overheat thermostat
Flue temperature probe NTC
Fuse 2 AF 250VAC 5x20
Temperature probe (D.h.w. circuit)
Detection electrode
Ignition electrode
Manufacturer’s
reference
SIT 848 Sigma 0848135
Watts
Watts
BI1001 102
BI1442 106
BI1441 501
BI1441 104
BI1431 101
BI1431 100
BI1262 118
BI1172 105
BI1432 102
BI1165 112
KI1042 501
BI1293 103
BI1293 102
ELTH - type 261
Short spare parts list
2
1
3
4
6
5
7
11
10
8
17
18
9
14
12
19
16
15
13
20
21
22
23
Figure 22.1
- 53 -
17962.2101.0271156A4UK
Biasi UK Ltd
Commercial Road
Leamore Enterprise Park
WALSALL
WS2 7NQ
Sales Tel. 01922 714600
Tech. Service Tel. 01922 714636
www.biasi.co.uk
N
08/07
2011
*1796221010*